Controller for monitoring and controlling pulsators in a milking system

ABSTRACT

A controller for monitoring and controlling an operating pulsator in a milking system is shown. The controller receives a start signal generated when a milking apparatus is attached to a cow. A first sensor is operatively connected to a designated pulsator for receiving a pulsating vacuum and for producing a first signal representing the pulsating vacuum level. The controller includes a processor having a comparator for comparing the first signal to a stored reference of predetermined vacuum ranges and for generating a control signal when the designed pulsator pulsating vacuum level is outside of a predetermined vacuum range. A control circuit signals that the designated pulsator pulsating vacuum level is outside of the predetermined vacuum range.

CROSS-REFERENCES TO RELATED APPLICATIONS

This Application is a Continuation-in Part of U.S. patent applicationSer. No. 11/248,958 filed Oct. 12, 2005 now U.S. Pat. No. 7,174,848which is a Continuation of U.S. patent application Ser. No. 10/359,834filed Feb. 7, 2003 and which has issued as U.S. Pat. No. 6,990,924.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO A “MICROFICHE APPENDIX” (SEE 37 CFR 1.96)

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to apparatus, method and system ofsupervising, monitoring and controlling all of the pulsators of amilking machine having a teatcup with a teatcup liner and a pulsationchamber comprising applying a milking vacuum to the interior of theteatcup liner and a pulsating vacuum to the pulsation chamber so thatthe teatcup liner cyclically moves between a substantially open positionand a substantially closed position under control of pulsation vacuumpulses from a pulsator and more particularity relates to a pulsatorcontroller for a milking machine comprising a teatcup with a teatcupliner and a pulsation chamber, a vacuum source for generating a milkingvacuum in the interior of the teatcup liner and a pulsator provided toalternately connect the pulsation chamber to the atmosphere and to thevacuum source for generating a pulsating vacuum in the pulsation chamberto produce a pulsating movement of the teat cup liner between asubstantially open position and a substantially closed position whereinthe controller signals that a designed pulsator pulsating vacuum levelis at a vacuum level outside of the predetermined vacuum range based ona stored reference signal received by a processor in a controllerrepresenting a predetermined vacuum range of pulsating vacuum levelsprogrammed as acceptable for milking system pulsators. The processor mayinclude a monitoring section to monitor the designated pulsator vacuumpulsation level and a pulsator section to control, actuate or deactuatethe vacuum pulsator to a milk claw.

2. Description of the Prior Art

Milking systems having a vacuum for performing milking of dairy animals,such as cows, are well known in the art. Certain of the milking systemshave the milking process for dairy animals, such as cows, automated tofacilitate faster and consistent milking of dairy animals.

A reference entitled MACHINE MILKING AND LACTATION by A. J. Bramley, F.H. Dood, G. A. Mein and J. A. Bramley, published by Insight books,Vermon, USA, describes the history, background and state of the art inmilking systems and in Chapter 7 entitled Basic Mechanics and Testing ofMilking Systems by G. A. Mein appearing at Pages 235 through 284,discloses and describes typical milking machine installations (the“Bramley et al. Reference”). U.S. Pat. No. 5,896,827 discloses a milkingsystem having a substantially stable continuous vacuum level through amilk claw and milk hose wherein the milking system includes a milkingapparatus for connection with an animal's teats to apply a controlledvacuum thereto to remove milk therefrom at various milk flow rates.

As milking systems become automated, milking system include monitoringapparatus for monitoring other functions in the milking system and forgenerating a signal if certain unacceptable operating condition occur.Examples of such monitoring apparatus are disclosed in the followingUnited States Patents.

U.S. Pat. No. 4,616,215 discloses a vacuum monitoring apparatus whichincludes a control circuit having a transducer for sensing the vacuumlevels in a milking system and for generating output signals. Thecontrol circuit includes a comparator for controlling indicator devicesand an alarm circuit in response to a set point when the vacuum levelsare at high, low and normal settings. The control circuit includes atime delay circuit that disables the alarm circuit for a predeterminedtime delay to provide for measurement of the vacuum recovery rate forthe system.

U.S. Pat. No. 4,605,040 discloses a partial-vacuum regulating valve thatautomatically regulates an operating partial vacuum in milking systems.The partial-vacuum regulating valve consists of a main valve and anauxiliary valve. The auxiliary valve body is adjusted in accordance withthe partial vacuum prevailing in the milking system and affects theamount of air that is drawn out of the main valve control chamber, whichcommunicates with the atmosphere through a calibrated bore, through acertain channel. The partial-vacuum is adjusted in the control chamberin accordance with the amount of air drawn out and that adjustmentdetermines the position of the auxiliary valve. The position of theauxiliary valve determines the amount of air flowing into a certain linethrough the air-inlet opening, which in, turn, affects the partialpressure in the line. The main-line control chamber has an additionalcalibrated air inlet that is closed off with a cap. When the cap isremoved, atmospheric air also flows through the additional inlet intothe main valve control chamber and reduces the partial vacuum therein.The associated descent of the valve body reduces the air admitted ontothe line and hence leads to partial pressure in the milking system thatis lower than the partial pressure established for the milking processby means of a screw and spring.

U.S. Pat. No. 4,572,104 discloses a method of milking for a doubleaction milking system. Milking is initiated at one ratio of milk periodand then increased to a selected higher ratio. Milking is then done atthe selected higher ratio for a selected segment of time or until themilk flow rate falls below a predetermined value, after which the ratiois decreased so that milking is completed at a lower ratio. A valve isused to selectively alternatively connect a line going to the teat cupsto vacuum or to atmospheric pressure.

U.S. Pat. No. 4,516,530 discloses an automated milking system in whichthe milking vacuum applied from a vacuum line through a milk flow valveand the milk hose to a teat cup cluster is initially shut off afterautomatic detacher controls provide a signal indicating the end ofmilking. A milk sweep controls a back flush system which passes aflushing fluid through the milk flow valve into the milk house and teatcup cluster to flush out these components.

U.S. Pat. No. 3,783,837 discloses a milking machine having a duct underpartial vacuum that leads milk from the teat cup cluster to form a milkflow having a milking flow rate. The duct has a regulating valve whichis used to vary the milking vacuum. A device for sensing changes in therate of milk flow through the duct is connected to control means foroperating the regulating valve to an idling value in response to adecrease in the milk flow rate and an increase in the milking vacuumfrom an idling value to a working value in response to an increase inthe rate of milk flow.

One example of automated dairy barn or milking parlor is a herringbonemilking stall parlor wherein the dairy animal is directed into a milkingstall. Once the dairy animal is in the stall a milking apparatus,comprising a milking claw and inflations, have the inflations thereofattached to the teats of a dairy animal to perform the milking processwhich commence when the milking vacuum is enabled or turned on. Theinflations are each formed of a separate teat cup and teat cup linerassembly that are attached to the teats of the dairy animal. Typicallythe inflations have four teat cup and teat cup liner assemblies, one foreach teat of a dairy animal, e.g. a cow.

Each teat cup has a shell and a teat cup liner is provided in the shellto form a pulsation chamber between the teat cup liner and the shell.During milking, the interior of the teat cup liner is subjected to avarying milking vacuum that typically varies over a range of about 10inches Hg to about 12 inches Hg and then to atmospheric pressure. Thepulsation chamber is subjected to a cyclically pulsating vacuum normallyvarying between atmospheric pressure, when the teat cup liner iscollapsed or closed, and a maximum vacuum level of about 12 inches Hgwhen the teat cup liner is fully open. The maximum pulsating vacuumlevel is normally about 12 inches Hg under atmospheric pressure, i.e.equal to the milking vacuum level. This means that the pressuredifference across the wall of the teat cup liner is essentially equal tozero when the teat cup liner is open.

In the state-of-the-art milking systems, the pulsating vacuum iscontrolled by a pulsator as described above. The pulsator has apulsation cycle which is divided into four phases; (i) an opening phase(a) during which the pulsating vacuum increases from atmosphericpressure to the milking vacuum level and the teat cup liner moves from aclosed position to an open position, (ii) an open phase (b) during whichthe pulsating vacuum has reached its maximum level, which issubstantially equal to the milking vacuum level, the teat cup liner isin an open position allowing milk to flow from a teat, (iii) a closingphase (c) during which the pulsating vacuum decreases from about themilking vacuum level to the atmospheric pressure and the teat cup linermoves from the open position to the closed position, and (iv) a closedphase (d) during which the pulsating vacuum is equal to the atmosphericpressure and the teat cup liner is in a closed position stopping milkflow from a teat. The above action of the pulsator is referred to hereingenerally as the “pulsation process”.

Each milking apparatus has a separate pulsator for controlling each teatcup shell and a teat cup liner by applying a vacuum to each pulsationchamber between the teat cup liner and the shell. The pulsator and thepulsation system is a vital part of a milking facility. There is usuallyone pulsator designated for each milking apparatus being used to milk adairy animal, e.g. a cow. If a milking parlor or milking barn has “N”milking apparatus all capable of milking cows at the same time, themilking parlor or milking barn would typically have “N” separatepulsators.

As discussed above, monitoring of the pulsation process, during whichthe teat cup liner movement occurs, is very important to the health andmilk production of a cow. Improper or defective operation of a pulsatoror a malfunction of a pulsator, if allowed to go unnoticed for aconsiderable period of time, can cause damage to the cow. Such damageresults because of trauma experienced by the teat of a dairy animalarising from improper teat cup liner movement and such damage couldinclude causing mastitis to the dairy animal.

Mastitis is an infection of animal body tissue within the mammary systemof an animal. Mastitis may be caused by a number of other conditionsincluding irritation to the teats, as is well known to persons skilledin the art. When mastitis occurs, it is an infection that the animal,e.g. cow's, body must counteract. Thus the animal's body energy is to beused to fight infection rather than produce milk.

If the infection is severe enough, significant and sometimes permanentdamage can be caused to the cow's normal milk producing organisms. Allmastitis cause some level of permanent and lifetime irrefutable damageto the animal's milk producing (mammary) system. The level of severityis in direct relation to the severity and length of time that aninfection exists. As such, a severe or lengthy period of infection maylimit the animal's production capabilities and affect the animal's milkproducing life.

A milking machine, milking apparatus or milking system generally causesmastitis in two ways.

First, mastitis is caused by application of damaging vacuum levels tothe cows' teats which create a severe irritation. Since it is difficultto isolate with any degree of certainty at what level of vacuum suchirritation occurs, the conservative approach is the least level ofvacuum, the better. Each animal, such as a cow, reacts differently tovacuums being applied to teats and each animal tolerates various levelsof vacuum differently.

Second, mastitis is created by a milking apparatus, causing foreignbacteria to be introduced into the animal, e.g. cow. As milk is beingdrawn from the cow, the teats are exposed to a vacuum which is less thanatmospheric pressure. However, the outside of the udder is underatmospheric pressure and, in essence, atmospheric pressure is what is“squeezing” the milk out of the animal's teats in response to a periodicpulsating or controlled vacuum from a pulsator.

If a pulsator is defective, is not operating properly or if amalfunction occurs affecting the pulsation process, it is desirable todetect and correct such a condition as soon as possible. Doing so willmost likely limit or prevent damage or injury to a dairy animal and helpmaintain the dairy animal in a healthy condition for giving milk. Adairy animal in good health produces a higher volume of milk during eachmilking cycle.

One known method for insuring proper operation of the pulsators andpulsation process is to test the milking system on a monthly basis usinga recorder for measuring vacuum levels of each of the pulsators and themeasuring the pulsation phases of the pulsation cycles. Based on thetest results, appropriate repairs can be made to the pulsator, vacuumlines and milking apparatus as required to remedy the identifieddeficiency or malfunction.

Between tests, an improperly operating pulsator or other malfunction ordeficiency in the milking system related to the pulsating process can gounnoticed for an extended period of time, sometimes as long a month,when the next test is scheduled to be conducted.

In the prior art monthly pulsator monitoring testing program, eachpulsator is tested on an individual basis and a determination is thenmade whether the pulsator operates within an acceptable standard. If thepulsator's operation is deficient or if the pulsator malfunctions, thepulsator is repaired or replaced, as necessary.

Other known apparatus for monitoring and controlling pulsators disclosedin certain United States Patents are discussed below.

U.S. Pat. Nos. 6,009,832 and 6,073,579 disclose a milking machine havinga teat cup with a teat cup liner and a pulsation chamber. The abruptmovement of the teat cup liner when the teat cup liner moves to an openor closed position is sensed. If a sensed movement does not fulfill apredetermined condition, a signaling means signals the malfunction.

U.S. Pat. No. 5,443,035 discloses a milking machine pulsation controlthat includes a micro controller which generates a pulse width modulateddrive signal to control current to pulsator valves, with a high currentfor pull-in and a lower current for holding. A watchdog circuit resetsthe computer in the event of latch-up as a result of circuit transients.

United States Patent Application Publication No. 2002/0104484 publishedon Aug. 8, 2002 which matured into U.S. Pat. No. 6,553,934 (Gentner etal) discloses a method and apparatus for monitoring the operation of apulsator by recording calibration data from that specific pulsatorduring a calibration mode made on that specific pulsator during normaloperations and using the so recorded pulsator specific calibration datafor comparison using a processor with data developed from that specificpulsator during milking operation and the processor provides a signal toan output, which signal indicates if the pulsator is operating.

None of the known prior art anticipates, discloses, suggests or teachesor a controller for monitoring and controlling pulsators in a milkingsystem wherein the referenced data stored in a computer system is aprogrammed standard for an acceptable predetermined vacuum range ofpulsating vacuum levels for a pulsator is predetermined for the milkingsystem. The programmed standard for an acceptable predetermined vacuumrange for a pulsator predetermined for the milking system is enteredinto and stored in the computer system as a reference standard formonitoring operation of all of the “N” pulsators in the milking system.The controller includes sensors and uses a start signal to verify that amilking apparatus is attached to a dairy animal at the commencement of amilking cycle.

In the method and apparatus for monitoring the operation of a pulsatordisclosed U.S. Pat. No. 6,553,934, each separate pulsator must becalibrated individually, recorded separately in a separate recordingstep and that calibration data can only be used with that specificpulsator during monitoring. If milking parlor or milking barn has “N”milking systems, then “N” pulsators must be separately calibrated, thatcalibration data must be stored as recorded data for each pulsator, andeach compare cycle is required to address each specific calibration datafor each specific pulsator.

In addition, the method and apparatus for monitoring the operation of apulsator disclosed in U.S. Pat. No. 6,553,934 does not anticipate,disclose, suggest or teach verifying that the milking apparatus isattached to a dairy animal during monitoring of the specific pulsator ofa specific milking apparatus to avoid generation of error signals. Noneof the known prior art anticipates, discloses, suggests or teaches or acontroller for monitoring and controlling pulsators in a milking systemwherein a processor within the pulsator controller receives a startsignal generated when a milking apparatus of a milking system isattached to a cow to be milked and for receiving a stop signal generatedwhen a cow being milked has reached the end of a milking cycle or amilking apparatus is disabled. In the present invention, the startsignal concurrently enables the processor to receive a first signalrepresenting the pulsating vacuum level from the designated pulsator andfor enabling operation of the designated pulsator to supply vacuumpulses to a milking apparatus. The processor is responsive to the stopsignal to concurrently disable receiving the first signal representingthe pulsating vacuum level from the designated pulsator and fordeactuating operation of the designated pulsator from supplying vacuumpulses to a milking apparatus. The above functions may be used foractivating/deactivating the monitoring of the pulsator. The monitoringfunction can also deactivate operation of the pulsator. Deactivating ofthe pulsation when a cow is not being milked has the additionaladvantage of saving wear and tear on the pulsator.

In cases where a dairy installation already has a pulsator controller,the monitoring function alone can be used. However, in such situations,when the monitoring is stopped in response to a “stop signal”, thepulsator may keep on working.

BRIEF SUMMARY OF THE INVENTION

The present invention discloses and teaches a new, novel and uniquecontroller for monitoring and controlling operating pulsators in amilking system. The controller for monitoring and controlling operatingpulsators in a milking system includes a first input configured to beoperatively connected to a designated pulsator for receiving thepulsating vacuum. A first sensor receives the pulsating vacuum andproduces a first signal representing the pulsating vacuum level receivedfrom the designated pulsator selected from an “N” number of pulsatorsoperating in a milking system. The controller further includes aprocessor operatively connected to the first sensor for receiving thefirst signal representing a pulsating vacuum level from the designatedpulsator being monitored. The processor includes a comparator forcomparing the first signal representing a pulsating vacuum level fromthe designated pulsator being monitored to a stored reference signalapplied to the processor from a computer and the stored reference signalrepresents a predetermined vacuum range of pulsating vacuum levelsprogrammed as acceptable for all milking system pulsators. The processorgenerates at least one control signal when the designed pulsatorpulsating vacuum level is at a vacuum level outside of the predeterminedvacuum range. A control circuit is responsive to the at least onecontrol signal for signaling that the designed pulsator pulsating vacuumlevel is outside of the range of pulsating vacuum levels programmed asacceptable for the milking system pulsators.

Therefore, it is an advantage of the present invention to provideapparatus, a system and method for monitoring and controlling operatingpulsators in a milking system.

Another advantage of the present invention is that a microprocessor inthe pulsator controller generates at least one control signal when themonitored pulsator pulsating vacuum level is at a vacuum level outsideof a programmed predetermined vacuum range.

Another advantage of the present invention is that the pulsatorcontroller has a control circuit for signaling that a monitored pulsatorpulsating vacuum level is outside of the range of pulsating vacuumlevels programmed as acceptable for the milking system pulsators.

Another advantage of the present invention is that the pulsatorcontroller control circuit is capable of disabling operation of themonitored pulsator having a pulsating vacuum level which is outside ofthe range of pulsating vacuum levels programmed as acceptable for themilking system pulsators.

Another advantage of the present invention is that the is that thepulsator controller can generate at least one of an acceptable controlsignal when the designated pulsator pulsating vacuum level is at avacuum level within the predetermined vacuum range programmed asacceptable for the milking system pulsators and an unacceptable controlsignal when the designed pulsator pulsating vacuum level is at a vacuumlevel outside of the predetermined vacuum range.

Another advantage of the present invention is that the pulsatorcontroller control circuit is responsive to an unacceptable controlsignal and to an acceptable control signal to enable a red illuminationdevice and a green illumination device, respectively.

Another advantage of the present invention is that the pulsatorcontroller can be used in a system for monitoring and controlling anoperating pulsator in a milking system.

Another advantage of the present invention is that the pulsatorcontroller can be used in a method for monitoring and controlling anoperating pulsator in a milking system.

Another advantage of the present invention is that the pulsatorcontroller verifies that the milking apparatus is attached to a dairyanimal during monitoring and that the milking vacuum is on to avoidgeneration of error signals.

Another advantage of the present invention is one of the known causes ofmastitis can be significantly reduced by using the pulsator controllerof the present invention which leads to greater milk production andimproved health of a dairy animal or cow.

Another advantage of the present invention is that the pulsatorcontroller includes a processor which receives a start signal which isgenerated when a milking apparatus of a milking system is attached to acow to be milked and a stop signal which is generated when a cow beingmilked has reached the end of a milking cycle or a milking apparatus isdisabled or deactuated.

Another advantage of the present invention is that the pulsatorcontroller includes a processor which is responsive to a start signal toconcurrently enable the processor to receive and monitor a first signalrepresenting the pulsating vacuum level from the designated pulsator andto actuate the designated pulsator to supply vacuum pulses to a milkingapparatus.

Another advantage of the present invention is that the pulsatorcontroller includes a processor that is responsive to the stop signal toconcurrently disable the processor from receiving and monitoring thefirst signal representing the pulsating vacuum level from the designatedpulsator and for deactuate operation of the designated pulsator fromsupplying vacuum pulses to a milking apparatus.

Another advantage of the present invention is that the pulsatorcontroller includes a processor that is responsive to a start signal toconcurrently enable a monitoring section of the processor to receive andmonitor a first signal representing the pulsating vacuum level from thedesignated pulsator and a pulsation section of the processor to actuatethe pulsation to supply vacuum pulses to the designated pulsator of amilking apparatus.

Another advantage of the present invention is that the pulsatorcontroller includes a processor that is responsive to a stop signal toconcurrently disable a monitoring section of the processor fromreceiving and monitoring the first signal representing the pulsatingvacuum level from the designated pulsator and a pulsation section of theprocessor for deactuating operation of the pulsator from supplyingvacuum pulses to the designated pulsator of a milking apparatus.

BRIEF DESCRIPTION OF THE DRAWING

The present invention will become more fully understood from thefollowing detailed description of a preferred but non-limitingembodiment thereof, described in connection with the accompanyingdrawings, wherein:

FIG. 1 is a pictorial representation of a milking system illustratingthe milking apparatus, milk claw, milk hose, control device, milk lineand associated components of the milking system;

FIG. 2 is a pictorial representation of a milking apparatus comprising amilk claw and four inflations wherein each inflation has a teat cuphaving a shell and a teat cup liner provided in the shell to form apulsation chamber between the teat cup liner and the shell and apulsator for providing pulsation vacuum level pulses to each inflationand a controller using the teachings of the present invention formonitoring and controlling the pulsator;

FIG. 3 is a chart plotting the milk flow rate as a function of timeduring a typical milking cycle of a cow;

FIG. 4 is a chart plotting vacuum level of the vacuum source as afunction of time during normal startup, operation of and shut-down ofthe vacuum system illustrated as part of FIG. 1;

FIG. 5 is a pressure/time graph showing by means of a continuous linehow the pulsating pressure in a pulsation chamber of a teat cup having ateat cup liner varies during a pulsation cycle;

FIG. 6 is a schematic representation of a pulsator controllerillustrated as being operatively connected to a pulsator of a milkingapparatus;

FIG. 7 is a schematic diagram of the overall data processing system forcontrolling and monitoring all pulsators in a milking system;

FIG. 8 is a detailed block diagram of a controller for practicing thisinvention;

FIG. 9 is a flow chart showing the steps of method of using the pulsatorcontroller for monitoring and controlling a pulsator;

FIG. 10 is message sub-routine flow chart showing the steps of method ofusing the pulsator controller for monitoring and controlling a pulsator;

FIG. 11 is a pictorial representation of monitor in a computer systemused for monitoring the pulsators in a milking system showing an alarmconfiguration for a designated pulsator;

FIG. 12 is a pictorial representation of monitor in a computer systemused for monitoring the pulsators in a milking system showing programmedstored reference signals to be applied to the processor from thecomputer system wherein the stored reference signal represents apredetermined vacuum range of pulsating vacuum levels programmed asacceptable for milking system pulsators;

FIG. 13 is a pictorial representation of monitor in a computer systemused for monitoring the pulsators in a milking system showing programmedphases of the pulsation cycle in milliseconds to be applied to all ofthe milking system pulsators;

FIG. 14 is a pictorial representation of monitor in a computer systemused for monitoring the pulsators in a milking system showing programmedphases of the pulsation cycle in percentage of a full pulsation cycle tobe applied to all of the milking system pulsators;

FIG. 15 is a block diagram illustrating another embodiment of theprocessor controller wherein the processor includes a control section, amonitoring section and a pulsation section and wherein the milkingsystem includes a detacher for generating a “start signal” and a “stopsignal” and a vacuum shutoff valve;

FIG. 16 is a graphical representation of a display device having awindow showing how data and information stored in the computer can bedisplayed for use as management information by a dairyman; and

FIG. 17 is a flow diagram of software for using data/instructions from acomputer to change programmed vacuum levels by computer programming, tochange pulsator on/off ratios and to change pulsation pulses.

DETAILED DESCRIPTION OF THE INVENTION

Before proceeding with the description of the preferred embodiment, thefollowing background will be helpful in understanding this invention.

Description of Milking System

When a cow enters a milking barn or milking parlor, such as a herringbone style milking parlor, and the milking machine or milking apparatusis connected to the animal's body and a milking vacuum is applied to theapparatus, the body starts to react in preparation for “letting down” ofthe diary animal's, e.g. cow's, milk. A natural process takes placewherein the animal produces within the animal's blood stream a chemicalcalled “oxitosin”. This chemical works its way down into the uddercausing the ovili cells to contract. In essence, contraction of theovili cells causes a squeezing effect to help push out, expel orwithdraw the animal's milk. The period of time the animal produces thisoxitosin is limited, and recent research suggests somewhere between 4minutes and 6 minutes on average.

Once an animal stops producing oxitosin, it becomes difficult, if notimpossible, to withdraw or remove any remaining milk from the animal.When milk is left in the udder of the animal, nature “tells” theanimal's body that it does not need to produce as much milk. Therefore,when this happens the animal's body will level off milk production andeventually decreases production during that lactation.

When a cow begins lactation, the cow increases its production of milkeach day as a natural response to “feed” the animal's growing baby calf.At some time during that lactation, the cow will naturally level off andthen begin a decrease in production. This is nature's way of “weaning”off the calf.

In the state-of-the art milking systems, monitoring of the pulsationprocess, during which the teat cup liner movement occurs, and monitoringof all of the pulsators, which control the teat cup liner movement, havebecome very important because an undetected defective or malfunctioningpulsator, can affect the health and milk production of a cow.

With this in mind, one can conclude it is important to that allpulsators are operating properly, otherwise the dairy animal couldsuffer damages to its teats which likely could result in the dairyanimal producing less milk. For these reason, properly operatingpulsators are important to the dairyman and the teachings of thisinvention will directly maintain the health of dairy animals and willenhance withdrawing of milk during the period of time the animal is“naturally” willing to give milk.

The pulsator controller for a milking system using the teachings of thisinvention represents an important advancement in the state-of-the-artdairies.

The pictorial drawing of FIG. 1 illustrates a milking system showinggenerally as 20 which is installed in a milk parlor operation having aplurality of vacuum-operated milking machines shown generally as 22 inindividual stalls.

In FIG. 1, a source of vacuum is provided to the milking system byvacuum pump 24 through a vacuum conduit 26 to a vacuum manifold header30. A vacuum regulator 32 is operatively connected to the vacuum conduit26 to control the maximum vacuum that would be applied to the milkingsystem. Typically, the vacuum level in a milking system is in the orderof 12 inches of Hg (12″ Hg).

The vacuum manifold header 30 is operatively coupled by a pulsation line36 to a pulsator 40.

The pulsation line 36 is generally a plastic or steel line that carriesvacuum, equal to the desired preset vacuum level, to the pulsator 40.Pulsation line 36 must be adequately sized to carry air away from thepulsator without allowing a drop in vacuum (lower than the milkingvacuum level).

The pulsator 40 is a device that intermittently applies pulsating vacuumpulse through flexible conduit 50 from within the shell (outside theliner) of the inflation 42 and creates a vacuum to “pull” to “open” theinflation 42 away from or releasing the teat of the cow making the teatopen so that the vacuum from the milk claw draws milk down thorough theteat. This is referred to as a “milk period”. Alternatively, atmosphericpressure is applied by the pulsation 40 to the liner to “push” or“close” the inflation 42 against the teat of the cow closing off theteat. This is referred to as a “rest period”. The pulsator 40periodically draws air out of the inflation 42 by application ofpulsating vacuum pulses at a controlled vacuum level to create the cycleof opening and closing of the teat cup liner. This creates a situationof milking (teat under vacuum) and rest (teat not under vacuum).

As illustrated in FIG. 1, the vacuum pump 24 removes air from themilking system to create less than atmospheric pressure within themilking system. The vacuum manifold header 30 is essentially adistribution manifold that allows both the milk line 76 and pulsationline 36 to have equal access to the vacuum source, which in thisembodiment is a vacuum pump 24 and vacuum regulator 32.

The vacuum regulator 32 is a vacuum level controller which is a devicethat maintains a predetermined or preset vacuum level within the milkingsystem 20. A typical vacuum pump 24 has capacity to draw vacuum levelslower than the levels desired in the basic milking system 20. The vacuumregulator 32 includes an air inlet to vary or balance the capacity ofthe vacuum pump 24 or to change the air introduced into the milkingprocess during normal operation. At times when the milking system 20 isintermitting air equal to the vacuum pump 24, the vacuum controller orvacuum regulator 32 will be off (no air inlet). When the milking systemis intermitting air less than the capacity of the vacuum pump 24capacity, the vacuum regulator 32 will open and “make-up” the differenceto maintain a constant and predetermined level of vacuum into themilking system 20 equal to the capacity of the vacuum pump 24.

Referring back to FIG. 1, the milking apparatus shown generally as 22has the inflations 42 which define the teat-engaging portion of a teatcup cluster. The milking apparatus 22 is adapted to have the inflations42 operatively connected or operatively attached with an animal's udder,such as for example a cow's udder 44, having teats 46 to apply acontrolled vacuum to the teats 46 to remove milk therefrom. Theinflations 42 include a shell and liner 48 which have an “open” and“closed” position depending upon the vacuum pressure applied thereto asdescribed hereinbefore. The vacuum pulsator 40 is operatively connectedby a flexible vacuum lines 50 to control the shells and liners 48.

The shells and liners 48, comprises two components. The first componentis a liner which is a soft rubber tube that goes around the cow's teat46 to seal it off from atmospheric pressure to allow the vacuum to drawmilk from the cow's udder 44. The other component is a shell which is arigid device that houses the liner and can seal the outside of the linerfrom atmospheric pressure. The shells and liners 48 cooperate toselectively or controllably apply vacuum to the cow's udder 44 and teats46 to withdraw the milk.

A milk claw 60, is operatively connected to the inflations 42 by meansof flexible tubing 62, to receive milk from the inflations 42 at variousmilk flow rates. The milk claw 60 receives and passes the milk under astabilized continuous vacuum in a vacuum channel at a selected vacuumlevel and, most importantly, at peak milk flow rates. The milk claw 60includes an outlet 64 having side walls and a predeterminedcross-sectional area, which in the preferred embodiment, is selected tobe in the range of: (i) a minimum cross-sectional area for maintainingat all milk flow rates a substantially uniform laminar flow of milkthere through and for concurrently providing a stabilized continuousvacuum in a vacuum channel between the laminar flow of milk and theinterior walls of the outlet 64; and (ii) a maximum cross-sectional areaequal to about 1.5 times the minimum cross-sectional area of the outlet64. Certain of the known prior art systems have a milk claw having anoutlet having a diameter of ⅝ inch. The teachings of this invention canbe used in all of the known prior art milking system having using any ofthe known milk claws.

In the preferred embodiment, the milk claw 60 has four (4) inflations 42since a cow has (4) four teats. The inflations 42, under controlledvacuum pressure from the pulsator 40, extracts milk from the cow's udder44 as described hereinbefore.

The milk claw 60 functions as a manifold device (claw) that brings themilk from four inlets into single outlet. The milk claw 60 further mayoptionally include a control orifice 70, which is in the form of acalibrated orifice, for controllably admitting atmospheric pressure tothe milk claw 60. Control orifice to functions for controlling thevacuum level within the milk claw outlet 64. Also, the milk claw 60 hasa housing 66 that has a central chamber 68 defined by sidewalls 69.

In the alternative, the inflations 42 may optionally include a controlorifice shown as 70′. Also, both the milk claw 60 and the inflation 42may each have a control orifice 70 and 70′ respectively, as the case maybe.

It is desirable to intermit air to the vacuum system at this point inthe milk claw 60 as the cow produces fluid milk, it would otherwise bedifficult to transport the milk away from the cow without approachingflooding. Therefore, the milk claw 60 may have an air bleed port orcontrol orifice 70 formed therein.

The milk claw outlet 64 is operatively connected by a milk transportconduit, shown generally as 72. The milk transport conduit 72 includes asemi-flexible hose 78 operatively connected to a nipple inlet 80 of amilk line 76.

The term “milk transport conduit” is intended to cover any flexibleconduit material such as a semi-flexible hose used in a milking system.Preferably, the milk transport conduit has a cross-sectional areasubstantially equal to the cross-sectional area of the outlet 64.

The term “milk transport conduit” is intended to also include any otherintermediate in line components, devices, control apparatus or the like(such as, for example, a milk flow measuring device 82 for terminatingor shutting off the vacuum at the end of a milking cycle shown inFIG. 1) vacuum sensing devices and the like.

In the embodiment illustrated in FIG. 1, the milk transport conduit isin the form of a semi-flexible clear plastic hose 78 which isoperatively connected to an inlet nipple 80 of the milk line 76. In thepreferred embodiment, the semi-flexible hose 78 is a plastic or rubberhose connecting the milking claw outlet 64 to the inlet nipple 80 asdescribed above.

The milk line 76, commonly referred to as a milk transfer line, is inthe form of a stainless steel line with adequate capacity to carryvacuum to the cow from the vacuum source 24. The vacuum manifold header30 applies vacuum via a conduit 84 and a moisture trap 86 to a receivingvessel such as a receiving jar 90 which is in the form of an enclosedvessel functioning as a vacuum chamber. The receiving jar 90 isoperatively connected to a milk pump 96 to remove the milk collected inthe receiving jar 90.

The milk line 76, under a vacuum which is applied thereto through thereceiving jar 90, transports the milk away from the cow to the receivingjar 90 where it is accumulated and pumped away by milk pump 96.

It is important for the milk transfer line 76 to have enough capacity tocarry milk away from all individual milking apparatus 22 while stillleaving adequate capacity to form a vacuum channel for unrestricted,stable, continuous closed vacuum system to the cow's udder 44.

The milk transfer line 76 and receiver jar 90 must be sized to haveenough capacity such that the milk flow will not fill the line, e.g.flood the line, which would block the vacuum channel and flow of vacuumto the milking apparatus 22 operatively connected to the cow's udder 44.

In addition, the milking system can have control valves, such as 82 and82′ which are used to enable or to turn on the milking vacuum on or todisable the milking vacuum or to turn off the milking vacuum. Thecontrol valves 82 and 82′ may include or cooperate with a sensor fordetecting whether the milking vacuum is on or off which is representedby lead line 136 and the sensor can generate a vacuum control signalverifying that the milking vacuum is present. The vacuum control signalcan be used as a verification signal for the monitoring and controlfunctions, as discussed hereinafter; or a “start signal” or a “stopsignal” can be produced using a detacher as discussed hereinafter.

Description of Operation

In operation, the milk line 76 is under a vacuum that is transportedthrough a vacuum channel in the milk hose 78 and milk claw 60 throughthe inflations to the cow's udder 44. The pulsator 40 periodicallyapplies vacuum to the inflation forming the “milk period” and “restperiod”. During the “milk period”, the vacuum is what “draws” the milkfrom the cow. If a vacuum was constantly applied on the cow's udder, theudder could be damaged. Therefore, it is necessary to “turn off” thatvacuum at regular intervals during the milking process. Typically, thatis on/off (milk/rest) ratio which is about between about 50% on-about50% off to about 70% on-about 30% off. These cycles are typically in theorder of between about 40 to about 60 times per minute.

This on/off cycle occurs within the inflation such that when the vacuumpassing through the vacuum channel of the milk line 76 reaches theinflation 42, the inflation collapses under that vacuum and pinches offvacuum to the cow's udder 44. To open the inflation, the pulsator 40applies an equal vacuum to the outside of the inflation 42 and pulls itopen causing vacuum to flow to the cow's udder and retract the animal'smilk. As the inflation 42 opens, vacuum will draw the milk from thecow's udder 44 where it is ultimately transported to the milk-receivingjar 90. To help move the milk thorough the system, one or more air bleedports or control orifices are introduced in the system as discussedabove including within the milking claw 60.

FIG. 1 illustrates diagrammatically the controller 104 for monitoringand controlling operating pulsators in a milking system. Controller 104is typical of a controller which would be operatively connected to eachone of all of the pulsators in the milking system. If the milking systemhas “N” milking apparatus, each milking apparatus would have a pulsatorsimilar to pulsator 40. Thus, each milking system having “N” pulsatorswould also have “N” controllers, one for monitoring each of thepulsators. As discussed herein below in FIG. 7, each pulsator isoperatively connected to and controlled through the controller by asystem computer having a memory which has as stored data therein in theform of a stored reference signal representing a predetermined vacuumrange of pulsating vacuum levels programmed as acceptable for all of themilking system pulsators. The system computer can control and/or programoperation of all pulsators by setting, controlling a monitoring allparameters such as phase periods, pulsation factors and the like.

The controller 104 has a first input 102 having a first sensor 106 whichis configured to be operatively connected to the pulsator 40 via vacuumtest port lines 108 which are operatively connected to the pulsationline 50 of the pulsator 40. The pulsator 40 has controlling solenoids 54which are operatively connected via power lead lines depicted by arrow52 to the controller 104 to apply a 24 volt, direct current power 130from the controller 104 to the operation of solenoids 54.

The controller 104 can control the application of power to and theremoval of power from controller 40 via power lead lines 52.

The controller 104 includes a processor 110 having a control device 112and a monitoring device 114. The processor 110 monitoring device 114 isoperatively connected to the first input 102 for receiving from thesensors 106 a first signal representing a pulsating vacuum level fromthe designated pulsator 40. The processor 110 control device 112includes a comparator for comparing the first signal to a storedreference signal representing a predetermined vacuum range of pulsatingvacuum levels programmed as acceptable for all milking system pulsators.The processor 110 control device 112 generates at least one controlsignal when the designated pulsator 40 pulsating vacuum level is at avacuum level outside of the predetermined vacuum range.

The control device 112 includes a control circuit which is responsive toat least one control signal for signaling that the designated pulsator40 pulsating vacuum level is outside of the range of pulsating vacuumlevels programmed as acceptable to the milking system pulsators. Analternative arrangement is discussed below with respect to block 552 inFIG. 15. The controller 104 including the processor 110 having thecontrol device 112 and the monitoring device 114 can communicate with aremote computer via a communication system represented by arrow 134.

As is apparent from the above discussions, when a problem is detected ina pulsator there are a number of options available to an operatorranging from recording the event to having the computer disable thepulsator.

In FIG. 1, the control device 112 utilizes the control circuit togenerate a signal by energizing a “red” illumination device to generatea visual signal that the pulsator has malfunctioned. The control device112 then may disable or shut off the 25-volt direct current power to thesolenoids 54 to deactuate and shut down the pulsator 40.

The processor 110 is configured to be able to control a designatedpulsator by activating the pulsator to allow vacuum pulses from a sourceof vacuum pulses to be applied to the designated pulsator. In addition,the processor 110 is able to deactuate a designated pulsator to stop thesupply of vacuum pulses being applied to the designated pulsator. If thepulsator determines that a designated pulsator has malfunctioned, insuch event, the control device 112 disables the designated pulsator.Therefore, depending on the programming of the processor, the designatedpulsator can be actuated or deactuated to control the application ofvacuum pulses from a source of vacuum pulses. The use of the term“disabled pulsator” as used herein applies to a designated pulsator ormonitored pulsator and is used to designate that an operating conditionexists where the processor has made determination that the designatedpulsator or the monitored pulsator is defective or has malfunctioned andis to be permanently “disabled”, shut off or otherwise to be removedfrom the milking system.

In an alternative embodiment, the control device 112 can energize a“green” illumination device to generate a visual signal that thepulsator is operating within pulsating vacuum levels programmed asacceptable for the milking system pulsators.

In still yet another alternative embodiment, the control device 112 canenergize a “yellow” illumination device to generate a visual signal thatthe pulsator is operating within pulsating vacuum levels programmed asminimally acceptable for the milking system pulsators.

FIG. 2 is a pictorial representation of a milking apparatus comprising amilk claw 60 and four inflations 42 wherein each inflation has a teatcup having a shell and a teat cup liner provided in the shell to form apulsation chamber between the teat cup liner and the shell. The milkingsystem includes the pulsator 40 for providing pulsation vacuum levelpulses over line 50 to each inflation 42 via conduits 150 and 152 to theinflation nipples 140 and the pulsation vacuum level is applied as aninput to the controller 104 for monitoring and controlling the pulsator40.

Referring now to the chart illustrated in FIG. 3, the chart plots ascurve 160 the milk flow rate as function of time during theabove-described milking cycle of a cow using the data set forth in Table1 above. Curve 160 shows that at the beginning of the milking cycle thatmaximum flow rate is reached with a minute or so. However, it takesabout two minutes or so at end of the cycle to reduce to a zero flowrate. A typical milking cycle is about 6 minutes.

In the chart illustrated in FIG. 4, the chart plots as curve 162 vacuumlevel operation established by the vacuum source as a function of timeduring normal startup operation and shut-down of the vacuum systemduring a 6 minute milking cycle. As illustrated, by curve 162 in FIG. 4,when the vacuum is turned on, it immediately reaches a preset vacuumlevel of 12 inches Hg (12″ Hg) which is the desired vacuum level andremains at that level until the end of the milking cycle.

In the pressure/time graph shown in FIG. 5, the continuous line 168illustrates how the pulsating pressure in a pulsation chamber of a teatcup having a teat cup liner varies during a pulsation cycle. During anopening phase a, depicted by 170 the pulsating pressure is decreasedfrom about atmospheric pressure to the milking vacuum or working vacuumas illustrated by 172. During the opening phase, the interior of theteat cup liner is open and milk can flow from the teat of a dairyanimal.

During the open phase b, the vacuum remains substantially at the workingvacuum. The duration of the open phase b is the time interval shown by172 and 174. During the open phase, the interior of the teat cup lineris kept open.

A closing phase c follows the open phase b and the pulsating pressureincreases from the milking vacuum or working vacuum level back to theatmospheric level and the time interval of the closing phase is shown by174 and 176. The closing phase results in the interior of the teat cupliner closing. The closing phase d, sometimes referred to as the restingphase, is essentially at atmospheric pressure and the time interval isshown by 176 and 178. During the close phase d, the interior of the teatcup liner is kept closed.

A pulsation cycle comprising the phases a through d usually last betweenabout 0.7 seconds to about 1.5 seconds.

In FIG. 6, the schematic representation of the controller 104 isillustrated as being operatively connected to a pulsator 40 of a milkingapparatus. Since each milking apparatus has a pulsator, each pulsatorwill have a controller 104 operatively connected thereto to monitor andcontrol operation of the pulsator 40 for the milk claw and inflations,as described above in connection with FIG. 1.

The controller 104 is operatively connected via a powered distributiondevice 184 to supply 24-volt direct current power over the common lead186 and to power leads 188 and 190, respectively. In addition, thevacuum test lines 108 from the controller 104 are operatively connectedto the pulsating lines 50. The pulsating vacuum level appearing onpulsating line 50 is carried by vacuum test lines 108 to the sensors106. The controller 104 has a “red” illumination device 120 and a“green” illumination device 124 to visually indicate whether thepulsating vacuum level from a designated pulsator is operating outsideof or within the range of pulsating vacuum levels programmed asacceptable for the milking system pulsators, respectively, all undercontrol of a control circuit of the monitoring device 144 of FIG. 1. Ayellow illumination device shown by dashed lines 122 may be used tosignal that the pulsator vacuum level is at a minimum acceptable levelfor milking pulsator.

The controller 104 is operatively connected to a source of 24 volts,direct current power, to a communication system to communicate with aremote computer, shown generally by arrow 372, and to receive a retractinput signal, which may in fact be a stop/start signal or milking/notmilking signal generated by a sensing unit as described below inconnection with FIG. 15, from the pulsator represented by the 132. Thus,the signal 132 as used herein represents a retract signal, stop/startsignal or a milking/not milking signal as the case may be and dependingon the application.

By using a stop/start signal or a milking/not milking signal, the systemis independent from having to detect if a vacuum is presently and usesthe stop/start signal or a milking/not milking signal for the system toknow that a cow is being milked or not milked.

FIG. 7 is a schematic diagram of the overall data processing system forcontrolling and monitoring all pulsators in a milking system. The dataprocessing system includes a computer 220 which functions as a systemprocessor. The term “computer” is intended to include all ancillarycomponents such as, without limitation, network servers, storage devicesincluding rotating disk memory storage systems, modems, communicationlines, digital subscriber lines (“DSL”), keyboards and the like.

The computer system is operatively connected by a communication system,shown generally by arrow 222 to each of the pulsator controllers in themilking system. In FIG. 7, milking system 1 is shown as having apulsator “1”, illustrated by 40, and a controller “1”, illustrated by104. The controller is operatively connected to a source of 24 voltsdirect current power 180 via power leads 186, 188 and 190. Thecontroller “1” illustrated as 104 as operatively to the communicationsystem 222 via conductors 224 to facilitate transfer data between thecomputer 220 and the controller “1” illustrated as 104. The controller“1” illustrated as 104 receives a signal indicating that the milkingvacuum is on verifying that the milking apparatus has been attached to adairy animal for milking and that a milking operation is to beperformed. The signal 132 is described herein represents a retractsignal, stop/start signal or a milking/not milking signal as the casemay be and depending on the application.

Since a milking system has “N” milking apparatus, each of the milkingapparatus has a controller, all of which are represented by controller“N” identified as 200 which are operatively connected to thecommunication system 222 via leads 226 and a pulsator “N” identified as204. Controller “N” identified as 200 likewise receives an input signalverifying that the milking vacuum for the milking system having thecontroller “N” illustrated by 200 is ready to commence a milking cycle.

The computer 220 via communication system 222 is operatively connectedto an annunciator 232 which functions as a locked display and alarmdevice. The annunciator 232 connected by leads 230 to the communicationsystem 222 can be actuated by the computer 220 showing the operatingaddition of all “N” pulsators in the milking system.

For example, if controller “1” illustrated generates at least onecontrol signal when the designated pulsator “1” depicted by 40 is at avacuum level outside of the predetermined vacuum range programmed asacceptable for the milking system pulsators, the controller “1”illustrated by 104 may optionally de-energize the pulsator “1” therebyterminating operation of that milking apparatus and the “red”illumination device 120 will be illuminated on the controller “1”illustrated by 104 and the same information would be visually providedat a selected remote location on the lock and display alarm 232.

The computer 220 contains in the computer memory the stored referencesignal representing a predetermined vacuum range of pulsating vacuumlevels programmed as acceptable for milking system pulsators. Thecomputer can bifurcate, under program control, the stored referencesignal into a first set of pulsating vacuum levels representing a rangeof pulsating vacuum levels programmed as highly acceptable for milkingsystem pulsators and a second set of pulsating vacuum levelsrepresenting a range of pulsating vacuum levels programmed as minimallyacceptable for milking system pulsators. The number of levels isoptional, and the goal is to identify a malfunctioning pulsator againsta set of parameters or variables that are compared against a reference.

In the controller, the processor would then generate a highly acceptablecontrol signal when the designated pulsator pulsating vacuum level is ata vacuum level within the predetermined vacuum range for pulsatingvacuum levels programmed as highly acceptable for milking systempulsators and a minimally acceptable control signal when the designatedpulsator pulsating vacuum level is at a vacuum level within thepredetermined vacuum range for pulsating vacuum levels programmed asminimally acceptable for milking system pulsators.

The control circuit of the pulsator controller would then be responsiveto the highly acceptable control signal and the minimally acceptablecontrol signal for providing appropriate signaling representing whetherthe designated pulsator pulsating vacuum level is at a vacuum levelwithin or outside of the predetermined vacuum range for pulsating levelsprogrammed as acceptable for the milking system pulsators.

The computer 220 can be operatively connected via lead 240 to theinternet 250 via lead 248 or to a telephone line 246 via a lead 244 totransfer data signals between the computer and a remotely locateddevice, such as a network server, either over the internet or telephoneline.

FIG. 8 is a detailed block diagram of a controller 220 for practicingthis invention. The controller 220 has a programmed microprocessor 260which functions as a local processor in the controller 220. Themicroprocessor 260 receives a verification signal that the milkingvacuum is on via lead 132. The microprocessor 200 communicates via lead262 through a network controller 264 and lead 266 to a network computer220 as illustrated in FIG. 7.

The microprocessor 260 receives a first signal representing a pulsatingvacuum level for the front pair of inflations through a first input 302and a pulsating vacuum level for the rear pair of inflation through asecond input 304. The pulsating vacuum from the front and rearinflations are applied to inputs 302 and 304 via the vacuum test linesto the vacuum test ports as illustrated by lead 300. The first input 302and a second input 304 have transducers or sensors which convert thepulsating vacuum level to a electrical signal which are applied vialeads 308 and 310, respectfully, to the programmed microprocessor 260.The programmed microprocessor 260 controls the front output 322 of thepulsator via lead 320 and the output of the front output 322 is appliedto the pulsator via leads 330. The programmed microprocessor 260controls the rear output 328 of the pulsator via lead 326 and the outputof the rear output 328 is applied to the pulsator via leads 330. Thepower to the controller 220 is provided by a 24 volt DC source 370. Theretract input signal or the stop/start signal 132 is applied to theprogrammed microprocessor 260. The programmed microprocessor 260controls the indicator lights 342 via led 340 to illuminate theappropriate red light 120, yellow light 122 and green light 124.

FIG. 9 is a flow chart showing the steps of method of using the pulsatorcontroller for monitoring and controlling a pulsator. In FIG. 9, a startsignal represented by flow chart item 400 and represents that a milkingcycle is to commence. The processor within the controller retrieves orreads the stored reference signals from the computer representing apredetermined vacuum range of pulsating vacuum levels programmed asacceptable for milking system pulsators. Absent a stop signal whichwould be generated by a stop signal 132 and which is represented by flowchart item 412 is applied to the start 400 as represented by arrow 420,the milking cycle can commence and the controller has verified that amilking vacuum is present and that the milking apparatus is in factattached to the dairy animal to be milked. In the alternative, thesystem may optionally include a sensor for determining the absence of orthe presence of a milking vacuum, which is represented by item 416. Theuse of a stop/start signal or a milking/not milking signal eliminatesthe need for determining if a milking vacuum is present as representedby 416. If a milking vacuum represented by item 416 is present, a “yes”input 414 of is applied to the stop signal represented by flow chartitem 412. In such event, the stop signal of item 412 applies a “yes” tothe start signal of flow chart item 400 enabling the system to startsince a milking vacuum is present. In the absence of a milking vacuumbeing present, a “no” signal represented by arrow 422 is applied as aninput to the read pressure sensors and save data of flow chart item 422and the system will then be disabled until a “yes” signal represented byarrow 414 is present enabling the stop signal 412 to advise the startsignal 400 that a milking vacuum is present

When all the inputs to the stop signal represented by flow chart 412 areyes, then the output from the stop signal flow chart 412 is no asrepresented by lead 422. Since all the appropriate inputs to the stopsignal of flow chart item 412 are yes, no stop signal is required andfor that reason a no appears on the lead 422.

The read pressure sensors and save data step as represented by flowchart item 424 is actuated sending an appropriate signal represented bylead 426 to the auto control mode represented by flow chart item 428.The auto control mode represented by flow chart item 428 can perform twofunctions based on whether or not an adjustment of timing of thepulsation cycle phases a through d is required. If an adjustment isrequired, then a yes signal is sent by auto control mode represented byflow chart item 428 via lead 430 to the step of adjust timing of phasesa, b, c and d to read from memory as represented by flow chart item 436.

If the auto control mode represented by flow chart item 428 decides thatno adjustment of timing is required, a no is communicated via lead 440to bypass the adjust timing represented by flow chart item 436.

If an adjust timing is required as represented by flow chart item 436,the output is applied to the step of set front and rear output levelsfor the pulsators as represented by flow chart item 438. The steprepresented by flow chart item 436 will respond to either an adjustinstruction from the adjust timing represented by flow chart item 436applied to the set front & rear output 438 as represented by arrow 434or to a no represented by lead 440. If an adjustment is not necessary,the step of responding represented by flow chart item 436 will thenrespond to the no received from the auto control mode of flow chart item428 represented by lead 440.

The instruction performed by the flow chart item 436 is represented bylead 446 which is applied to the step of comparing to be performed bythe processor as represented by flow chart item 448. The processorperforms the step of comparing a first signal representing the pulsatingvacuum level received from a designated pulsator to a stored referencesignal, subject of flow chart item 402, representing a predeterminedvacuum range of pulsating vacuum levels programmed as acceptable formilking system pulsators.

The instruction subject of flow chart item 448 is to set or enable agreen, if present and available, a yellow or a red illumination deviceaccording to the pulsation state. In addition, instruction subject offlow chart item 448 would include disabling a designated pulsator whichis determined by the controller. Also, in accordance with theinstruction subject of flow chart item 448, a warning signal can be sentto a remote computer which monitors the entire milking system operationadvising of the enabling of a yellow illumination device, if present,and warning of the enabling of a red illumination device whichrepresents that the designated pulsator pulsating vacuum level isoutside of the range of pulsating vacuum levels programmed as acceptablefor all of the milking system pulsators.

In certain instances, the process may trigger a message sub-routinerepresented by: (i) flow chart item 406 which is responsive to a noinstruction generated by the start signal of flow chart item 400 and(ii) message sub-routine 406′ which is responsive to an instructiongenerated by the set in warning instructions generated by the flow chartitem 448 which is applied via lead 450 to the message sub-routinerepresented by flow chart item 406′, the output of which is applied backto the start signal instruction of flow chart 400, which output isrepresented by lead 456. The steps of the message sub-routinerepresented by flow chart items 406 and 406′ are discussed below inreference to FIG. 10.

FIG. 10 is message sub-routine flow chart for flow chart item 406′ ofFIG. 9 showing the steps of method of using the pulsator controller formonitoring and controlling a pulsator. The message sub-routine flowchart of FIG. 10 also applies to the flow chart item 406 of FIG. 9.

In FIG. 10, the input to the message sub-routine 406 is represented bylead 450. The instructions is applied to a check data/instructions fromcomputer represented by flow chart item 470. Upon completion of theinstructions represented by flow chart item 470 the output is applied toa data/instructions step represented by flow chart item 474, the inputto which is represented by lead 472. If the data/instructionsrepresented by flow chart item 474 determines that no instructions arenecessary as represented by lead 490, the no instructions is applied tothe output represented 482 from the message sub-routine 406′. Ifinstructions are required, a yes instruction is generated as presentedby lead 478 and the yes instruction is applied to a processdata/instructions from computer as presented by flow chart item 480. Theoutput from the processing step represented by flow chart item 480 isthen applied to the output represented by lead 482.

FIG. 11 is a pictorial representation of monitor in a computer systemused for monitoring the pulsators in a milking system showing an alarmconfiguration display 500 for a designated controller. The alarmconfiguration display 500 discloses information relating to a designatedpulsator which is one of a “N” number of pulsators in the milkingsystem. The computer system can generate an alarm system display forevery one of the “N” number of pulsators in the same format illustratedin FIG. 11.

In FIG. 11, the alarm configuration page 500 shows the setting rates andratios, represented by 502, the setting system variables, represented by504, the setting alarm parameters, represented by 508, if present, theminimum acceptable pulsating vacuum levels used for enabling a yellowillumination device is represented by 510 and the production of anunacceptable pulsating vacuum level signal which triggers the enablingof a red illumination device and the optionally disabling of a pulsatoris represented by 512. In addition, the pulsating cycle times inmilliseconds are represented by phase as shown by 514.

FIG. 12 is a pictorial representation of monitor in a computer systemused for monitoring the pulsators in a milking system showing on adisplay page 520 programmed stored reference signals to be applied tothe processor from the computer system wherein the stored referencesignal represents a predetermined vacuum range of pulsating vacuumlevels programmed as acceptable for milking system pulsators and thepulsator configuration 524 controls the on/off time of the pulsators asdepicted by the pulsation display section 526. In FIG. 12, the alarmlevels are set in milliseconds for phases a through d and a maximum andminimum vacuum in inches of Hg as shown by the data in box 528. Box 528shows that the monitored values are averaged over three cycles. If ayellow illumination device is present in the monitoring system, theinformation contained in box 528 designates the minimum and maximumtimes to trigger or enable the yellow illumination device.

A red illumination device is present in the monitoring system for thereasons discussed above. The information contained in box 528 designatesthe minimum and maximum times to trigger or enable the red illuminationdevice. Also, the information contained in box 528 for the triggering orenabling the red illumination device can concurrently be used by thecontroller to optionally disable the designated pulsator when thatdesignated pulsator pulsing vacuum level is at a vacuum level outside ofthe predetermined vacuum range programmed as acceptable for the milkingsystem pulsators.

FIG. 13 is a pictorial representation or monitor in a computer systemused for monitoring the pulsators in a milking system showing on adisplay page 530 real time values applied to all of the milking systempulsators. In addition, a continuous line representing the pulsatingcycle is displayed as line 532 on the monitor. This cycle information isavailable for each one of the “N” pulsators in a control system.

In addition, the display page 530 includes a section showing additionalinformation about the periods of each of the pulsation cycle phases athrough d as well as relevant information. The computer can displayabsolute data for the last cycle as represented by item 534 and candisplay the same information based on a three cycle average asrepresented by item 536.

FIG. 14 is a pictorial representation of monitor in a computer systemused for monitoring the pulsators in a milking system showing a displaypage 530′ programmed phases of the pulsation cycle in percentage of afull pulsation cycle to be applied to all of the milking systempulsators. The information displayed on the display page of 530′ of FIG.14 is substantially identical to the display page 530 of FIG. 13 exceptthat the last cycle data represented by 534′ and a three cycle averagedata by 536′ is shown in percentages of the pulsating cycle. Thedisplayed information relating to cycle information shown by line 532′is identical to the information shown by line 532 in FIG. 13.

The following examples are provided:

Pulsation Cycle Examples

Pulsator Example Phase a Phase b Phase c Phase d Ratio A 10 50 20 2060:40 B 10 55 20 15 65:35 C 10 40 20 30 50:50 D 18 44 15 23 62:38 E 1248 12 28 60:40 F 10 60 15 15 70:30

The teachings of the present invention equally applied to a method andsystem for utilizing the controller for monitoring and controlling apulsator as disclosed herein.

The pulsator controller can be used in a method for monitoring andcontrolling an operating pulsator in a milking system. The methodcomprises the steps of: producing with a first sensor a first signalrepresenting the pulsating vacuum level from a monitored operatingpulsator; comparing with a processor the first signal representing apulsating vacuum level from the monitored operating pulsator to a storedreference signal representing a predetermined vacuum range of pulsatingvacuum levels programmed as acceptable for milking system pulsators; andgenerating with a processor at least one control signal when themonitored operating pulsator pulsating vacuum level is at a vacuum leveloutside of the predetermined vacuum range.

In addition, the method may further comprise the step of signaling witha control circuit responsive to the at least one control signal that themonitored operating pulsator pulsating vacuum level is outside of therange of pulsating vacuum levels programmed as acceptable for themilking system pulsators.

In addition, the method may further comprise including signaling with afirst signaling device in responsive to the at least one control signalthat a monitored operating pulsator pulsating vacuum level is outside ofthe range of pulsating vacuum levels programmed as acceptable for themilking system pulsators.

In addition, the method may further comprise the step of disabling withthe control circuit in responsive to the at least one control signal themonitored operating pulsator having a pulsating vacuum level outside ofthe range of pulsating vacuum levels programmed as acceptable for themilking system pulsators and has malfunctioned and is to be permanentlydisabled.

Also, the pulsator controller can be used in a system for monitoring amilking system. The milking system has a plurality of milking apparatuseach having inflations and wherein each of the milking apparatus have apulsator for controlling with pulsating vacuum the inflations when amilking apparatus is attached to a dairy animal and a milking vacuum ispresent in the milking apparatus. A source of milking vacuum is appliedto each of the milking apparatus, e.g. one pulsator per milk claw percow per stall. A plurality of pulsator controllers are included in themilking system and one of each of the pulsators is designated for adesignated one of the plurality of milking apparatus. Each of thepulsator controllers comprise a power input for receiving electricalpower; a first input operatively connected to a pulsator to be monitoredin a milking system for receiving from the monitored pulsator apulsating vacuum; a first sensor operatively connected to the firstinput for producing a first signal representing the pulsating vacuumlevel in the monitored pulsator; a processor operatively connected tothe power input for receiving electrical power and to the first sensorfor receiving the first signal, the processor including a comparator forcomparing the first signal to a stored reference signal applied to theprocessor from a computer wherein the stored reference signal representsa predetermined vacuum range of pulsating vacuum levels programmed asacceptable for milking system pulsators, the processor generating atleast one control signal when the monitored pulsator pulsating vacuumlevel is at a vacuum level outside of the predetermined vacuum range. Acontrol circuit is responsive to the at least one control signal for atleast one of signaling that the monitored pulsator pulsating vacuumlevel is outside of the range of pulsating vacuum levels programmed asacceptable for the milking system pulsators and disabling operation ofthe monitored pulsator pulsating vacuum level which is outside of therange of pulsating vacuum levels programmed as acceptable for themilking system pulsators.

The system may include the computer having the stored reference signalswhich represent the predetermined vacuum range of pulsating vacuumlevels programmed as acceptable for milking system pulsators isoperatively connected to each of the plurality of pulsator controllersby a communication system.

In addition, the system may include the control circuit being responsiveto the at least one control signal for signaling with a first signalingdevice that the monitored pulsator pulsating vacuum level is outside ofthe range of pulsating vacuum levels programmed as acceptable for themilking system pulsators.

In addition, the system may include the processor generating at leastone of an acceptable control signal when a designed pulsator pulsatingvacuum level is at a vacuum level within the predetermined vacuum rangeprogrammed as acceptable for the milking system pulsators and anunacceptable control signal when a designed pulsator pulsating vacuumlevel is at a vacuum level outside of the predetermined vacuum rangeprogrammed as acceptable for the milking system pulsators.

In addition, the system may include the control circuit being responsiveto the unacceptable control signal for signaling with a first signalingdevice that the monitored pulsator pulsating vacuum level is outside ofthe range of pulsating vacuum levels programmed as acceptable for themilking system pulsators.

In addition, the system may include the control circuit being responsiveto the acceptable control signal for signaling with a second signalingdevice that the monitored pulsator pulsating vacuum level is within therange of pulsating vacuum levels programmed as acceptable for themilking system pulsators.

In an overview, the computer controller monitoring and control isoperable to control one component in a milking system. For example, if apulsator controller signal to the computer that a yellow illuminationdevice is activated or enabled, the computer can tract the pulsator andindependently generate a warning signal in response to a programmingmonitoring criteria.

Controller for Controlling and Monitoring an Operating Pulsator

As shown in FIG. 1, the embodiment of the controller 104 includes aprocessor 110 having a control device 112 and a monitoring device 114.The monitoring device 114 is operatively connected to the first input102 for receiving from the sensors 106 a first signal representing apulsating vacuum level from the designated pulsator 40. The controldevice 112 includes a comparator for comparing the first signalrepresenting a pulsating vacuum level from the designated pulsator 40 toa stored reference signal representing a predetermined vacuum range ofpulsating vacuum levels programmed as acceptable for all milking systempulsators. The control device 112 generates at least one control signalwhen the designated pulsator 40 pulsating vacuum level is at a vacuumlevel outside of the stored reference signal representing apredetermined vacuum range of pulsating vacuum levels programmed asacceptable for all milking system pulsators.

In FIG. 15, the controller 104 is configured such that the processor 110includes a control section 112 and a controlling and monitoring systemhaving two sections, namely a monitoring section 550 and a pulsationsection 552.

The monitoring section 550, as described above, basically uses thesensors 106, as vacuum test ports, to read vacuum levels and to generatea first signal representing the sensed vacuum levels. The processor 110then uses the first signal for operating decisions. The monitoringsection 550 calculates the value of phases A, B, C and D and comparesthe calculated values therefor with stored reference signals, e.g.limits, to trigger events or alarms.

The pulsation section 552 performs the function of opening and closingpulsator valves 54 shown in FIG. 1 in order to create or establish apulsation cycle such as the pulsation cycle depicted in FIG. 5. In FIG.1, the coils 54 are part of a pulsator 40 and when energized willmechanically open a valve connected between the pulsation line 36,sometimes known as a vacuum pipe, and the vacuum test port lines 108,sometimes known as pulsation vacuum hoses, as shown in FIG. 1. Thisenables a vacuum to pass from the pulsation vacuum pipe 36 to thepulsation vacuum hose 108.

The pulsator 40, which is controlled by the pulsation section 552 asdepicted by arrow 560, intermittently applies pulsating vacuum pulsesthrough the flexible conduit 50 from within the shell (outside theliner) of the inflation 42 and creates a vacuum to “pull” to “open” theinflation 42 away from or releasing the teat of the cow 44 making theteat open so that the vacuum from the milk claw 66 draws milk downthorough the teat. This is referred to as a “milk period”. As describedabove, alternatively atmospheric pressure is applied by the pulsation 40to the liner to “push” or “close” the inflation 42 against the teat ofthe cow 44 closing off the teat all shown in FIG. 1. This is referred toas a “rest period”. The pulsator 40 periodically draws air out of theinflation 42 by application of pulsating vacuum pulses at a controlledvacuum level to create the cycle of opening and closing of the teat cupliner. This creates a situation of milking (teat under vacuum) and rest(teat not under vacuum).

The energizing and de-energizing of coils 54 is performed by thepulsation section 552 via control 560 which controls the energizing andde-energizing of coils 54 according to a preset rate or programmed rateor programmed sequence. For example, the programmed rate having anon/off ratio of 60/40 is depicted by the pulsation display section 526on the left side of FIG. 12.

The pulsation section 552 may perform or enable the pulsation to occurindependently in a preprogrammed manner or ratio without any feedback orfeed back signals from the monitoring section 550. However, it isenvisioned that the pulsation section 552 may be programmed to modify orchange the pulsation ratio or pulsator settings “on the fly” or in realtime in order to compensate for possible errors detected by themonitoring section 550. In certain circumstances, it may not bepractical to modify or change the pulsator ratio or pulsation settingbecause some of the detected pulsator problems cannot be remedied orovercome by changing, modifying or otherwise re-programming theprogrammed pulsation rate and/or ratio. In the preferred embodiment ofthe controller 104 as described above in connection with FIG. 1, thepulsating function is programmed to operate at a preselected ratio orrate and the pulsator ratio or rate is not “controlled” by themonitoring section 550 or the pulsating section 552. The monitoringsection 550 is configured to detect when a pulsator problem exists andto inform a user when an operating problem is detected.

Thus, in the preferred embodiment, the monitoring section 550 isindependent of the pulsation section 552.

In the alternate embodiment of the controller 104 as described above inconnection with FIG. 15, the pulsation section 552 can be responsive tofeedback, feedback signals or control signals depicted by arrow 556 fromthe monitoring section 552 to the control 112 to modify, change, vary,deactuate or otherwise re-program the programmed operation of thepulsator section 552 which controls the pulsator 40 via control 560.This would enable or permit a computer system, e.g. micropulsatorprocessor 110 or a separate or remote computer system 220, as shown inFIG. 7, to program, re-program or control the pulsator section 552 asdepicted by arrow 558. The pulsation section 552 is responsive tocontrol, actuate, deactuate or otherwise control its associated pulsator40.

For example, a pulsator 40 can be programmed or operated by anelectronic pulsation system, e.g. coils 54, that are programmed,operated or run by an electronic pulsation system. The pulsator can bemonitored by the monitoring section 550 as is known to person's skilledin the art. Thus, the pulsator controller 104 depicted in FIG. 15 can beprogrammed to: (i) perform both a monitoring function and a pulsationcontrol function, (ii) just perform a monitoring function and notperform a pulsating control function, or (iii) the pulsator controller104 can just perform the pulsating control or programming function andnot perform the monitoring function.

In summary, the pulsator controller 104 of the present invention can usethe monitoring section 550 or the pulsation section 552 alone or incombination to monitor and/or control and/or actuate and/or deactuatethe pulsator vacuum to the pulsator 40 and/or monitor, detect, and/orsignal and/or report a pulsator 40 malfunction. In certain instances,the pulsator controller 104 can include a processor operativelyconnected to a memory or to a remote computer 220 having a memory forstoring pulsator malfunction criteria as a reference table and storedreference signals representing a predetermined vacuum range of pulsatingvacuum levels programmed as acceptable for milking system pulsators. Theprocessor 110 can be programmed to disable a malfunctioning pulsator asa “disabled pulsator” as discussed above.

The processor 110 is operatively connected to the first sensor forreceiving the first signal representing the pulsating vacuum level fromthe designated pulsator 40. The processor 110 would include a comparatorfor comparing the first signal to the stored reference and the processorwould generate at least one control signal when the designed pulsatorpulsating vacuum level is at a vacuum level outside of the predeterminedvacuum range. At least one information signal may be generated by theprocessor from the pulsator malfunction criteria reference tableidentifying the pulsator malfunction represented by the at least onecontrol signal.

Controller for Monitoring and Controlling an Operating Pulsator in aMilking System having a Start Signal as a Verification Signal and a StopSignal

Generally the function of controlling pulsation and of monitoring thepulsator 40 can be achieved by including or incorporating all of thenecessary or required electronics or components in an electronic board.This structure or configuration provides the pulsator controller 104with another important operating feature; that is, the pulsation section552 is capable of stopping or interrupting the pulsation when a cow, asdepicted as cow's teats 44, is not being milked. The pulsation sectionis responsive to a “start signal” to start the pulsation control andmonitoring function. The “start signal” is essentially a verificationsignal that the milking apparatus has been attached to the cow to bemilked.

Typically a pulsation system has just one or a single “controller” foroperating all of the dairy pulsators in a milking system. Such a designis economical as the use of a single controller reduces the cost of thedairy milking system components. One problem associated with a one orsingle “controller” configuration for operating all of the dairypulsators is that all pulsators must be operating all of the time.Therefore, a user cannot start or stop any one of the dairy pulsators atthe same time to accommodate for the fact that every cow starts and endsa milking cycle at different times.

In the present invention, each pulsator 40 has a controller 104 insuringthat, in the milking system using the teachings of this invention, thereis one controller per dairy pulsator. One advantage of thisconfiguration is that a user or dairyman can now operate or program theoperation of the pulsation for each pulsator 40 independently perpulsator which can be performed for each cow. When a cow is beingmilked, the specific or designated pulsator for the cow can beindependently activated. This results in reducing the “wear and tear” oneach pulsator, which is both desirable and economical.

Start Input Signal

As discussed above, the pulsation controller 104 has an input referredto herein as a “start signal”. The “start signal”, or input signal, isshown in FIG. 1 as 136 which is labeled “milking system on”. The “startsignal” can be developed from a variety of input devices or sources, allof which are well known to persons of ordinary skill in the art. Oneexample of a device for generating or producing a “start signal” or a“milking signal” is a Flow Nexus scanner sold by Beco Dairy AutomationInc. which starts a clock in response to a start signal or milkingsignal which is generated when a milking apparatus attached to a cowcommences a milking cycle. The clock stops at the end of a milking cycleand the milking time can be displayed.

In FIG. 15, a detacher 562 is responsive to the vacuum in the clawcluster 66 via conduit 566 and to a feedback signal depicted by arrow568 from the milk sensor 82 depicting the amount of milk sensed by themilk sensor 82 to shut off or move the stop/start button to a “stop”position in the detacher 562 in response to the control signal 568 fromthe milk sensor 82.

As discussed above in connection with FIG. 1, the milk claw outlet 64 isoperatively connected to a milk transport conduit, shown generally as72. The milk transport conduit 72 includes a semi-flexible hose 78operatively connected to a nipple inlet 80 of a milk line 76. A vacuumshut off valve, known as a VSO valve 580, shown in FIG. 15, may belocated in the milk transport conduit 72 between the milk hose 78 andmilk line nipple 80. The VSO valve 580 is normally open when a cow isbeing milked enabling the milk to pass to the milk line 76. When a cowis not being milked, the VSO valve 580 is closed. When the VSO valve 580is closed, there is no vacuum present at the liners 70 shown in FIG. 1.Therefore, the milk claw 66 attaches to the cow because the milk claw 66will not attach to the cow's teats 66 and the milk claw 60 will fall offof the cow.

The use of a VSO valve is exemplary and a “stop” signal or a “start”signal can be generated using sensors or other devices such as forexample external electronic boards to detect milking or not milking.

The detacher 562 has a manual mode, e.g. where the stop/start buttondepicted by dashed circle 564 is manually actuated to the “stop”position. The detacher 562 has an automatic mode, e.g., where thedetacher'senses that the cow has reached the end of a milking cycle viathe control signal 568 from the milk sensor 82, that automaticallyactuate the stop/start button 564 into the “stop” position.

A user can actuate the stop/start button 564 of the detacher 562 to the“start” position. In response, the detacher 562 automatically sends asignal depicted by arrow 570 and 572 to open the VSO valve 580. When theuser actuates the stop/start button 564 of the detacher 562 to the“stop” position, the detacher 562 sends a signal via 570 and 572 toclose the VSO valve 580.

An end of a milking cycle results in the closing of the VSO valve 562and this is determined by the user actuating the stop/start button 564into the “stop” position (detacher in manual mode), or can be determinedby the detacher 562 itself (detacher in automatic mode).

The pulsator controller 104 monitors the VSO valve 580 status throughthe signals on line 572 which is used as the input signal 136. Forpurposes of this discussion, this input signal 136 is sometimes referredherein as the “start signal”.

In operation, by knowing the status of the VSO valve 580 or monitoringthe position of the “stop/start” button 564 of the detacher 562, theuser knows if a cow is being milked or not being milked at any time.When the “stop/start” button 564 is in the “start” position, a “startsignal” is produced. When the “stop/start” button is in the “stop”position, a “stop signal” or “end of milking cycle signal” is produced.

Line 572 transmits the “start signal” or the “stop signal” to the inputsignal line 136, shown in FIG. 1, of the controller 104.

As such, signal line 136 functions as a system input for the controller104 enabling the processor 110 to respond to the “start signal” or “stopsignal”, as the case may be.

In the embodiment of FIG. 15, the processor 110 is responsive to a startsignal applied to the input or system input to concurrently enableoperation of the designated pulsator to supply vacuum pulses to amilking apparatus and to commence monitoring of said first signalrepresenting the pulsating vacuum level from the designated pulsator. Inaddition, the processor is responsive to a stop signal applied to theinput or designated pulsator from receiving a supply of vacuum pulsesfrom a source supplying vacuum pulses to a milking apparatus and todisable monitoring of the first signal representing said pulsatingvacuum level from the designated pulsator.

The pulsator controller 104 uses that input signal 136 as “start signal”for several functions: (i) to operate the monitoring and/or pulsatingfunctions only when a cow is being milked; and (ii) to collect milkingdata such as start of milking cycle, end of milking cycle, volume ofmilk and the like and enabling the data and/or information to be storedas stored information in a computer or memory and to be analyzed and/orused for dairy management purposes. Each of these functions arediscussed hereinbelow.

Operation of the Monitoring and/or Pulsating Functions only when a Cowis being Milked

The monitor pulsation system has can be operated during the monitoringfunction and/or pulsating function only when a cow is being milked. Theadvantages of monitoring only when a cow is being milked are:

(a) The pulsation cycles, phases A, B, C and D values, are differentwhen a cow is attached to the milk claw, the “attached mode” than when acow is not attached to the milk claw, the “unattached mode”. It isbetter to program alarms limits only for the “attached mode”. If thealarms limits are programmed to accommodate both the “attached mode” andthe “unattached mode”, the total alarm limits bandwidth is wider thatthe bandwidth for the “attached mode” alone. As a result, the alarm orvacuum level limits will have a wider bandwidth and this may result insome desired limit values or vacuum reference values for alarm limitsbeing exceeded or missed due to the wider bandwidth. Thus, by monitoringthe cow only in the “attached mode”, the bandwidth of the alarm limitsis tighter and the alarm limits can be more precisely programmed in the“attached mode” which is highly desirable to a dairyman.

(b) The pulsation systems may be shut-off or in the “off mode”, when acow is not being milked. If the monitoring function is enabled with thepulsation system in the “off mode”, the monitoring system would continueto monitor even though the pulsator is in the “off mode”. The monitoringsystem would detect a problem with the pulsator because the pulsator isnot in an “on mode” for milking a cow even though the pulsator is infact in the “off mode” as a cow is not being milked.

In the embodiment of the controller 104 depicted in FIG. 15, thepulsation section 552 performs or controls the pulsation controlfunction of the pulsator 40 via control 560 through the coils 54 whichare powered by the 24 VDC and common electrical leads as depicted inFIG. 1. In operation, when the milking system is in the “off mode”, thepulsators are in the “off mode”, e.g. deactuated. Therefore, in theembodiment depicted in FIG. 15, the monitoring section 550 is placed inthe “off mode” to disable the monitoring function and to avoidtriggering a false alarm.

One advantage of the embodiment depicted in FIG. 15 is that when themilking system is in the “off mode” and the pulsators are in the “offmode”, a significant amount of “wear and tear” on all of the pulsatorsis eliminated. In a typical milking operation and for about 50% of thetime, there is no cow being milked in a stall.

Accordingly, when a cow is not being milked, a controller 104 isresponsive to a “stop signal” or an “end of milking cycle signal” forplacing the pulsators in the “off mode” and this is highly desirable toa dairyman from both a cost aspect and a maintenance aspect due to thereduction in the “wear and tear” on the pulsators.

In addition, the controller 104 is also responsive to a beginning ofmilking cycle signal or a “start signal” designating commencement of themilking cycle for a single cow in a single stall which actuates orenables a designated pulsator for that specific cow being milked in adesignated stall. As such, this is also highly desirable to a dairyman.

This eliminates actuating all of the pulsators for all cow-milking clawsat the same time thereby insuring that the pulsation is not“synchronized”. In this embodiment of the controller 104 depicted inFIG. 15, every stall starts and ends pulsation at different timesdepending on the occurrence of the “start signal” for that designatedcow in the designated stall. As a result of the non-synchronization ofthe pulsators, there is less vacuum fluctuation in the main vacuum line.

Collecting and Storing Data from Milking Events

The monitoring section 550 of the controller 104 sends signals viacommunication link 134 to a remote computer or to a main computerrepresenting events such as for example, the “start signal”, the “end ofmilking cycle signal”, event signals such as detected alarms or problemsin the pulsator. This information and data is stored in a memory of themain computer, or in the alternative, in a memory in the controller,e.g., the memory used for the programmed microprocessor processor 260shown in FIG. 8. Such information and data is in the form of a historythat a dairyman can use for management decisions.

The Table illustrated FIG. 16 is an example of how the data andinformation is stored in the computer and how that data and informationcan be displayed by an appropriate output device having a screendepicted by arrow 600. The main computer software can be programmed forthe desired display of the stored information in the computer memory.

The screen 600 displays a window 604 showing the displayed informationderived from the stored data or information in the memory. In thedisplay of FIG. 16, the horizontal axis 606 depicts the time of day witheach “tick” representing a minute. The vertical axis 610 represents thestall for each cow being milked, by individual stall number, asillustrated by arrow 612.

When the detacher 562 generates a “start signal”, the “start signal” isshown by arrow 620 for stall 622. The “start signal” represented byarrow 620 is the beginning of a rectangular shaped graphicrepresentation 624 depicting a milking cycle for the designated cow install 622.

When the detacher 562 generates a “stop signal”, representing the end ofa milking cycle”, the “stop signal” is shown by arrow 626 for stall 622.The “stop signal” represented by arrow 626 is the end of the rectangularshaped graphic representation 624 depicting a milking cycle for thedesignated cow in stall 622. As such, each cow being milked in adesignated stall is represented by a rectangular shaped graphicrepresentation similar to 624.

A square shaped graphic representation 630 depicts that a problem wasdetected in that pulsation for that stall by the monitoring section 550.

A significant amount of management data and information can be extractedfrom the Table depicted in the display 600. For example, the dairymancan check how long it takes to change cows as depicted by area 634, howlong it takes to milk a string of cows as depicted by area 636 or theorder in which the dairyman's milkers attached the milking claws to thecows which is depicted by the variation in the alignment of the “startsignals” depicted by arrow 640.

Thus, the software systems for the present invention differs from theknown software systems in that the system disclosed and taught hereinalso shows pulsation alarms in the window 604 of display 600.

Software Flow Diagram for Changing Programmed Vacuum Levels, Pulsatoron/off Ratios and Pulsation Pulses

As discussed above, a stored reference signal representing apredetermined vacuum range of pulsating vacuum levels is programmed inthe form of data/instructions from a computer. The programmed vacuumlevels can be changed by computer programming at any time. In operation,the programmed vacuum levels can be changed by computer programmingprior to the start of a milking cycle or during a milking cycle. Theprogrammed vacuum levels are the pulsating vacuum levels acceptable formilking system pulsators.

The data instructions from the computer can be also used to changepulsator on/off ratios and to change the pulsation pulses.

A flow diagram of software for using data instructions from a computeris shown by FIG. 17. The data/instructions are used to change programmedvacuum levels by computer programming, to change pulsator on/off ratiosand to change pulsation pulses.

In FIG. 17, data/instructions from the computer shown at 660 isresponded to by the software to change programmed vacuum levels asdepicted by box 662. If the change programmed levels occur during amilking cycle, the software directs the system to either: (1) retain theoriginal programming vacuum levels programmed at the start of milkingcycle until end of milking cycle as depicted by the triangle 666; or (2)use a new programmed vacuum levels programmed during the milking cycleas depicted by rectangle 668.

If the programmed vacuum levels are changed prior to the start of amilking cycle, the software will retain original programmed levelsthroughout the milking cycle following the instructions shown byrectangle 666.

In addition, the data/instructions from the computer depicted by 660 canbe used to change the pulsator on/off ratio as depicted by box 672. Thepulsator on/off ratio can be changed at any time prior to start of amilking cycle or during a milking cycle as depicted by rectangle 674.

In addition, the data/instructions from the computer depicted by 660 canbe used to change the pulsation pulses as depicted by box 678. Thepulsation pulses can be changed at any time prior to start of a milkingcycle or during a milking cycle as depicted by rectangle 680.

The changes made to the software in response to the data/instructionsfrom the computer depicted by 660 is supplied to the controller asdepicted by arrow 682. The controller is responsive to the appropriatesignals from one of the rectangles 666, 668, 674 and 680 to perform theprogrammed changes.

All of the above teachings apply to a system for concurrently milking anumber cows in individual milking stalls in a cow barn. In the preferredembodiment, the system comprises a milking system having a plurality ofmilking apparatus each having inflations and wherein each of the milkingapparatus have a pulsator for controlling with pulsating vacuum theinflations when a milking apparatus is attached to a dairy animal, e.g.a cow, and a milking vacuum is present in the milking apparatus. Thesystem includes a source of milking vacuum applied to each of themilking apparatus. A plurality of pulsator controllers, one of eachbeing designated for a designated one of the plurality of milkingapparatus, are used for each cow milking stall. Each of the pulsatorcontrollers comprising a power input for receiving electrical power anda system input for receiving a start signal generated when a milkingapparatus of a milking system is attached to a cow to be milked and forreceiving a stop signal generated when a cow being milked has reachedthe end of a milking cycle or a milking apparatus is disabled. Thepulsator controller also includes a first input operatively connected toa pulsator to be monitored in a milking system for receiving from themonitored pulsator a pulsating vacuum and a first sensor operativelyconnected to the first input for producing a first signal representingthe pulsating vacuum level in the monitored pulsator. Each pulsatorcontroller includes a processor operatively connected to the power inputfor receiving electrical power and to the system input for receiving astart signal or a stop signal and to the first sensor for receiving thefirst signal. The processor is responsive to a start signal applied tothe system input for commencing monitoring of the first signalrepresenting the pulsating vacuum level from the designated pulsator andfor enabling operation of the designated pulsator to supply vacuumpulses to a milking apparatus. The processor is responsive to the stopsignal to terminate monitoring of the first signal representing thepulsating vacuum level from the designated pulsator and to deactuateoperation of the designated pulsator in supplying vacuum pulses to amilking apparatus in response to a stop signal applied to the input.

The pulsator controller includes a control circuit which is responsiveto the at least one control signal for signaling that the monitoredpulsator pulsating vacuum level is outside of the range of pulsatingvacuum levels programmed as acceptable for the milking system pulsators.

In the system, the stored reference signal representing a predeterminedvacuum range of pulsating vacuum levels programmed as acceptable formilking system pulsators may be: (i) derived from a pulsator; or (ii)programmed in the form of data/instructions from a computer and whereinthe programmed vacuum levels can be changed by computer programming andsuch programmed vacuum levels are the pulsating vacuum levels acceptablefor milking system pulsators.

It is envisioned that the pulsator controller in substantially thepreferred embodiment or a variation thereof may have utility for otherdairy animals, such as goats. It will be appreciated that variousalterations and modifications may be made to the pulsator controller toenhance the functional characteristics thereof. All such variations andmodifications should be considered to fall within the scope of theinvention as broadly hereinbefore described and as claimed hereafter.

All such uses, variations, modifications and the like are anticipated tobe within the scope of this invention.

1. A controller for monitoring and controlling an operating pulsator ina milking system, said controller comprising: an input for receiving astart signal generated when a milking apparatus of a milking system isattached to a cow to be milked; a first sensor configured to be aoperatively connected to a designated pulsator for the milking apparatusattached to a cow to be milked for receiving a pulsating vacuumtherefrom and for producing a first signal representing the pulsatingvacuum level received from the designated pulsator; a processoroperatively connected to said input and to said first sensor, saidprocessor being responsive to said start signal to commencing monitoringof said first signal representing said pulsating vacuum level from thedesignated pulsator, said processor including a comparator for comparingsaid first signal to a stored reference signal representing apredetermined vacuum range of pulsating vacuum levels programmed asacceptable for milking system pulsators, said predetermined vacuum rangecomprising a value determined from pulsators that are independent fromthe milking system, said processor generating at least one controlsignal when the designed pulsator pulsating vacuum level is at a vacuumlevel outside of the predetermined vacuum range, the processorconfigured for monitoring only while the milking apparatus is attachedto the cow to be milked; and a control circuit responsive to said atleast one control signal for signaling that the designated pulsatorpulsating vacuum level is outside of the range of pulsating vacuumlevels programmed as acceptable for the milking system pulsators.
 2. Thecontroller of claim 1 wherein said input receives a stop signalgenerated when a cow being milked has reached the end of a milking cycleor a milking apparatus is disabled and wherein said processor isresponsive to said stop signal to disable monitoring of said firstsignal representing said pulsating vacuum level from the designatedpulsator.
 3. The controller of claim 2 wherein the processor includes amonitoring section operatively to receive said first signal representingsaid pulsating vacuum level from the designated pulsator for enablingoperation of the monitoring section to monitor said first signalrepresenting said pulsating vacuum level from the designated pulsator inresponse to a start signal and for disabling operation of the monitoringsection from monitoring said first signal representing said pulsatingvacuum level from the designated pulsator in response to a stop; and apulsation section operatively connect to a designated pulsator forenabling operation of the designated pulsator to supply vacuum pulses toa milking apparatus in response to a start signal and for deactuatingoperation of the designated pulsator in supplying vacuum pulses to amilking apparatus in response to a stop signal.
 4. The controller ofclaim 3 wherein said processor is responsive to a start signal toconcurrently to commence monitoring of said first signal representingsaid pulsating vacuum level from the designated pulsator and enableoperation of the designated pulsator to supply vacuum pulses to amilking apparatus.
 5. The controller of claim 3 wherein said processoris responsive to a stop signal to concurrently disable monitoring ofsaid first signal representing said pulsating vacuum level from thedesignated pulsator and deactuate operation of the designated pulsatorsupplying vacuum pulses to a milking apparatus.
 6. The controller ofclaim 1 wherein the stored reference signal representing a predeterminedvacuum range of pulsating vacuum levels programmed as acceptable formilking system pulsators is derived from a pulsator.
 7. The controllerof claim 1 wherein the stored reference signal representing apredetermined vacuum range of pulsating vacuum levels programmed asacceptable for milking system pulsators is programmed in the farm ofdata/instructions from a computer and wherein said programmed vacuumlevels can be changed by computer programming and such programmed vacuumlevels are the pulsating vacuum levels acceptable for milking systempulsators.
 8. The controller of claim 1 wherein said processor generatesat least one of an acceptable control signal when the designatedpulsator pulsating vacuum level is at a vacuum level within thepredetermined vacuum range programmed as acceptable for the milkingsystem pulsators and an unacceptable control signal when the designedpulsator pulsating vacuum level is at a vacuum level outside of thepredetermined vacuum range programmed as acceptable for the milkingsystem pulsators.
 9. The controller of claim 8 wherein said controlcircuit is responsive to said acceptable control signal for signalingthat the designated pulsator pulsating vacuum level is within the rangeof vacuum levels programmed as acceptable for the milking systempulsators.
 10. The controller of claim 8 wherein said control circuit isresponsive to said unacceptable control signal for signaling that thedesignated pulsator pulsating vacuum level is outside of the range ofpulsating vacuum levels programmed as acceptable for the milking systempulsators.
 11. The controller of claim 1 wherein said control circuit isresponsive to said at least one control signal for sending data over acommunication system to a receiving device that the designated pulsatorhas a pulsating vacuum level outside of the range of pulsating vacuumlevels programmed as acceptable for the milking system pulsators. 12.The controller of claim 1 wherein said processor retrieves said storedreference signal representing a predetermined vacuum range of pulsatingvacuum levels programmed as acceptable for milking system pulsators froma separate computer operatively connected to said processor.
 13. Amethod for monitoring and controlling an operating pulsator in a milkingsystem comprising the steps of: receiving a start signal which isgenerated when a milking apparatus of a milking system is attached to acow to be milked; producing with a first sensor a first signalrepresenting the pulsating vacuum level from the operating pulsator;monitoring the operating pulsator only during period when the milkingapparatus is attached to the cow to be milked; comparing with aprocessor and commencing upon receipt of a start signal said firstsignal representing a pulsating vacuum level from the monitoredoperating pulsator to a stored reference signal representing apredetermined vacuum range of pulsating vacuum levels programmed asacceptable for milking system pulsators, the predetermined vacuum rangecomprising a value determined from pulsators that are independent fromthe milking system; and generating with a processor at least one controlsignal when the monitored operating pulsator pulsating vacuum level isat a vacuum level outside of the predetermined vacuum range.
 14. Themethod of claim 13 further comprising the step of signaling with acontrol circuit responsive to said at least one control signal that themonitored operating pulsator pulsating vacuum level is outside of therange of pulsating vacuum levels programmed as acceptable for themilking system pulsators.
 15. The method of claim 14 further wherein thestep of signaling includes signaling with a first signaling device inresponsive to said at least one control signal that a monitoredoperating pulsator pulsating vacuum level is outside of the range ofpulsating vacuum levels programmed as acceptable for the milking systempulsators.
 16. The method of claim 13 wherein the step of comparingutilizes a stored reference signal representing a predetermined vacuumrange of pulsating vacuum levels programmed as acceptable for milkingsystem pulsators derived from a pulsator.
 17. The method of claim 13wherein the step of comparing utilizes a stored reference signalrepresenting a predetermined vacuum range of pulsating vacuum levelsprogrammed as acceptable for milking system pulsators is programmed inthe form of data/instructions from a computer and wherein saidprogrammed vacuum levels can be changed by computer programming and suchprogrammed vacuum levels are the pulsating vacuum levels acceptable formilking system pulsators.
 18. The method of claim 13 further comprisingthe step of receiving a stop signal generated when a cow being milkedhas reached the end of a milking cycle or a milking apparatus isdisabled and wherein said processor is responsive to said stop signal todisable monitoring of said first signal representing said pulsatingvacuum level from the designated pulsator.
 19. The method of claim 13further comprising the step of receiving a stop signal generated when acow being milked has reached the end of a milking cycle or a milkingapparatus is disabled and wherein said processor is responsive to saidstop signal to concurrently deactuate the operation of the designatedpulsator supplying vacuum pulses to a milking apparatus and of themonitoring section from monitoring of said first signal representingsaid pulsating vacuum level from the designated pulsator.